Wire-arc additive manufacturing of pre-forms for forging of a Ti–6Al–4V turbine blade

Sizova, Irina; Hirtler, Markus�; Günther, Martin; Bambach�, Markus

doi:10.1063/1.5112693

Cited by 19 publications

(4 citation statements)

References 14 publications

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“…Basically, two process routes are possible: (i) AM and subsequent forming or (ii) forming and subsequent AM. The first hybrid processing route was extensively studied by authors of the present work in regard to Ti-6Al-4V [9][10][11]. It was observed that Ti-6Al-4V pre-forms for forging made either by L-PBF or by WAAM show a good hot workability.…”

Section: Introductionmentioning

confidence: 81%

Residual Stress and Microstructure of a Ti-6Al-4V Wire Arc Additive Manufacturing Hybrid Demonstrator

Mishurova

Sydow

Thiede

et al. 2020

Metals

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Wire Arc Additive Manufacturing (WAAM) features high deposition rates and, thus, allows production of large components that are relevant for aerospace applications. However, a lot of aerospace parts are currently produced by forging or machining alone to ensure fast production and to obtain good mechanical properties; the use of these conventional process routes causes high tooling and material costs. A hybrid approach (a combination of forging and WAAM) allows making production more efficient. In this fashion, further structural or functional features can be built in any direction without using additional tools for every part. By using a combination of forging basic geometries with one tool set and adding the functional features by means of WAAM, the tool costs and material waste can be reduced compared to either completely forged or machined parts. One of the factors influencing the structural integrity of additively manufactured parts are (high) residual stresses, generated during the build process. In this study, the triaxial residual stress profiles in a hybrid WAAM part are reported, as determined by neutron diffraction. The analysis is complemented by microstructural investigations, showing a gradient of microstructure (shape and size of grains) along the part height. The highest residual stresses were found in the transition zone (between WAAM and forged part). The total stress range showed to be lower than expected for WAAM components. This could be explained by the thermal history of the component.

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Section: Introductionmentioning

confidence: 81%

Residual Stress and Microstructure of a Ti-6Al-4V Wire Arc Additive Manufacturing Hybrid Demonstrator

Mishurova

Sydow

Thiede

et al. 2020

Metals

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“…In this case, the build time in AM is reduced by approximately 50% for this geometry. Manufacturing of Ti-6Al-4V pre-forms by WAAM for subsequent forging was studied by Sizova et al [17]. The pre-forms can be used for the manufacturing of turbine blades, which would be manufactured conventionally in several consecutive forging operations.…”

Section: State Of the Artmentioning

confidence: 99%

Alternating Additive Manufacturing and Forming—An Innovative Manufacturing Approach

Papke

Hafenecker

Römisch

et al. 2023

JMMP

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In this work, an innovative manufacturing approach that includes a fully linked and integrated manufacturing system consisting of a laser-based directed energy deposition (DED-LB/M) module and a forming press is presented. The alternating additive manufacturing (AM) process is based on a combination of a DED-LB/M process using a laser power of 600 W and a feed rate of 400 mm/min and a subsequent forming process, in which the structure is upset with a hydraulic press using a constant forming force of 500 kN in order to smooth the surface and influence the accuracy of the components. For the generation of a fundamental process understanding, a cuboid, basic shape was chosen as geometry for the investigations. The aim is to improve part properties by applying the process steps to generate part properties, which are superior to solely additive manufactured material. It is shown that the geometry of additive manufactured structures can be adapted, and the top surface can be smoothed due to the forming operation. The mean roughness value Rz decreases up to 50% after the forming operation. The hardness can be increased by work hardening. Of special interest is that the higher hardness can be kept up even though a further DED-LB/M process step and forming operation are applied to the additively manufactured and formed structure again. Finally, an analysis of the new manufacturing approach regarding its potential is given.

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“…Sizova et al [16] investigated the thermal deformation behavior of Ti-6Al-4V samples made by WAMM (Wire-Arc Additive Manufacturing) at 850 • C and 950 • C and discovered that its stress level was 20% lower than the average. The metallographic microscope revealed that practically all WAMM materials had completed the spheroidization kinetics of the α phase.…”

Section: Introductionmentioning

confidence: 99%

Hot Tensile Deformation Behavior of Ti-6Al-4V Titanium Alloy Made by Laser Melting Deposition

et al. 2022

Machines

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The combined process of additive manufacturing (AM) and subsequent hot forming technology enables the low-cost and rapid manufacturing of complicated structures with local features that cannot be manufactured monolithically by traditional forming technologies. The thermal deformation properties of as-deposited materials from AM require investigation. In this paper, laser melting deposition (LMD) was used to prepare as-deposited Ti-6Al-4V samples; high-temperature tensile tests for as-deposited titanium alloy were performed at different strain rates (0.001 s−1, 0.005 s−1, 0.01 s−1) and temperatures (650 °C, 700 °C, 750 °C) using the electrically assisted high-temperature tensile test system. The results show that the material’s flow stress level was negatively correlated with temperature and positively correlated with strain rate. EBSD and TEM were used to characterize the microstructure of the samples. The acicular martensite in the original material began to disintegrate under the influence of high-temperature tension, coarsening the lamella and splitting the boundary. The proportion of high-angle grain boundaries after deformation increased significantly from 81.4% to 87.5–90.7%. The results of the micromorphology observations indicate that the micro-deformation mechanism for deposited Ti-6Al-4V samples at high temperatures is mostly discontinuous dynamic recrystallization and dynamic spheroidization.

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Wire-arc additive manufacturing of pre-forms for forging of a Ti–6Al–4V turbine blade

Cited by 19 publications

References 14 publications

Residual Stress and Microstructure of a Ti-6Al-4V Wire Arc Additive Manufacturing Hybrid Demonstrator

Residual Stress and Microstructure of a Ti-6Al-4V Wire Arc Additive Manufacturing Hybrid Demonstrator

Alternating Additive Manufacturing and Forming—An Innovative Manufacturing Approach

Hot Tensile Deformation Behavior of Ti-6Al-4V Titanium Alloy Made by Laser Melting Deposition

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